Apparatus and method for manufacturing a smoking article pack

ABSTRACT

Apparatus and Method for Manufacturing a Smoking Article Pack An apparatus ( 10 ) for manufacturing a sealed pack ( 20, 34, 36, 37 ) of smoking articles ( 2 ) and modifying an internal atmosphere thereof. The apparatus ( 10 ) comprises a handling mechanism ( 13 ) for conveying a sealed pack ( 20 ) of smoking articles ( 2 ) within the apparatus ( 10 ). The handling mechanism ( 13 ) includes a support plate ( 24 ) against which a pack ( 20 ) abuts during conveyance by the handling mechanism ( 13 ). The support plate ( 24 ) includes a gas port ( 29 ). The apparatus ( 10 ) is configured such that, as a pack ( 20 ) is conveyed by the handling mechanism ( 13 ) in abutment with the support plate ( 24 ), the gas port ( 29 ) may engage a valve ( 4 ) formed in the pack ( 20 ) to enable a gaseous atmosphere within the sealed ( 20 ) pack to be modified. Also, a method of manufacturing a pack ( 37 ) of smoking articles ( 2 ) by means of such an apparatus ( 10 ).

FIELD OF THE INVENTION

This invention relates to an apparatus and method for manufacturing a pack for smoking articles.

BACKGROUND

It is known to provide packs of smoking articles that comprise a bundle of smoking articles in a generally rectangular parallelepiped configuration, an inner frame of card across the front and side faces of the bundle, and an outer wrapper of film or other barrier material enclosing the bundle to form an airtight pack. Such packs are known to include an access aperture for a user to remove smoking articles from the pack, and a re-sealable label over the access aperture to enable the pack to be sealed closed.

Such known packs may be provided within an outer box formed from a blank of card and comprising a body having an open top and a hinged lid attached to the body and moveable to open or close the open top.

It is also known to provide packaging as an airtight container and to package goods in such a container with the interior of the container having a reduced pressure or a vacuum, or being of an atmosphere less reactive than ambient air, to prevent the contents of the container from spoiling by reaction with oxygen in air and to increase the shelf-life of the container contents.

It is desirable to produce a smoking article pack comprising a sealed container with a reduced interior pressure or less reactive interior atmosphere. However, it is problematic to provide a cost-effective means of producing such packs without the requirement of a bespoke, and thereby expensive, manufacturing machinery. It is also desirable to be able to reliably produce such packs in a high-speed production process.

The present invention seeks to provide an alternative apparatus and method of manufacturing smoking article packs that alleviates or overcomes the above problems.

SUMMARY

According to the present invention, there is provided an apparatus for manufacturing a sealed pack of smoking articles and modifying an internal atmosphere thereof, the apparatus comprising a handling mechanism for conveying a sealed pack of smoking articles within the apparatus, the handling mechanism including a support plate against which a pack abuts during conveyance by the handling mechanism, the support plate including a gas port, the apparatus configured such that, as a pack is conveyed by the handling mechanism in abutment with the support plate, the gas port may engage a valve formed in the pack to enable a gaseous atmosphere within the sealed pack to be modified.

The support plate may comprise one of a pair of spaced support plates configured to retain a pack between the support plates, wherein at least one of the support plates includes the gas port.

The apparatus may comprise a plurality of gas ports. At least two gas ports may be provided on the same support plate. Each support plate may comprise a gas port.

The or at least one gas port may include a sealing element to facilitate formation of an airtight seal between the gas port(s) and the pack.

The or at least one gas port may comprise an aperture extending through the support plate.

The or each gas port may comprise a suction port connected to a vacuum source to enable air to be evacuated from a pack through the suction port.

The or each gas port may comprise a filling port connected to a pressurised gas source to enable a pack to be filled with gas from the pressurised gas source through the filling port.

The or each gas port may comprise a suction and filling port selectively connected to a vacuum source and a pressurised gas source to enable air to be evacuated from a pack through the gas port and for a pack to be filled with gas from the pressurised gas source through the gas port.

A first gas port may comprise a suction port connected to a vacuum source to enable air to be evacuated from a pack through the suction port, and a second gas port may comprise a filling port connected to a pressurised gas source to enable a pack to be filled with gas from the pressurised gas source through the filling port.

A control valve may be provided between the or each gas port and the source of vacuum and/or pressurised gas supply, and the or each control valve may be operable to control communication of the source of vacuum and/or pressurised gas supply with the or each gas port.

The or one of the support plate(s) may include a sensor element configured to detect when a pack is supported in abutment with the support plate, and the or each control valve may be configured to be actuated when it is detected that a pack is in abutment with the support plate.

The apparatus may further comprise a controller connected to the or each control valve to control operation thereof. The sensor element may be connected to the controller.

The apparatus may comprise a wrapping station configured to wrap and seal a bundle of smoking articles with a barrier material to form a sealed package and to provide a valve on at least one face of the package, and to provide the sealed package to the handling mechanism.

The wrapping station may include a continuous web of barrier material having valves at regularly spaced intervals along the web, each valve disposed over an aperture through the barrier material, and wherein the wrapping station may be configured to cut sections of barrier material from the web and to wrap and seal bundles of smoking articles such that the or each valve is consistently positioned on each sealed package.

The apparatus may further comprise a packing station configured to form an outer box around the sealed package, and the handling mechanism may be disposed between the wrapping station and the packing station to convey the sealed package between the wrapping station and the packing station.

The apparatus may further comprise an adhesive applicator configured to apply an adhesive to the sealed package or an interior surface of the outer box, to bond the sealed package to the outer box with the adhesive applied over the or at least one valve of the sealed package.

The or at least one gas port may be configured to sit over the or at least one valve on the wrapped package when engaged therewith, and the or at least one gas port may be of a larger dimension than the or at least one valve.

The or at least one gas port and the or at least one valve may be substantially circular and the or at last one gas port may be of a greater diameter than the diameter of the or at least one valve.

The present invention also provides a method of manufacturing a sealed pack of smoking articles having a modified internal atmosphere using an apparatus comprising a handling mechanism which includes a support plate having a gas port, the method comprising conveying a sealed pack of smoking articles within the apparatus using the handling mechanism with the pack abutting the support plate, engaging the gas port with a valve formed in the pack and modifying the gaseous atmosphere within the sealed pack via the valve through the gas port.

The method may comprise conveying the pack held between the support plate and a second support plate whilst modifying the internal atmosphere within the pack.

The gas port may comprise a suction port connected to a vacuum source and the step of modifying the gaseous atmosphere within the sealed pack may comprise evacuating air from within the sealed pack through the suction port.

The gas port may comprise a filling port connected to a source of pressurised gas and the step of modifying the gaseous atmosphere within the sealed pack may comprise filling the sealed pack with gas from the pressurised gas source through the filling port.

The gas port may comprise a suction and filling port selectively connected to a vacuum source and a pressurised gas source, and the step of modifying the gaseous atmosphere within the sealed pack may comprise evacuating air from within the sealed pack through the gas port and filling the sealed pack with gas from the pressurised gas source through the gas port.

The apparatus may comprise a first gas port comprising a suction port connected to a vacuum source and a second gas port comprising a filling port connected to a pressurised gas source, and the step of modifying the gaseous atmosphere within the pack may comprise evacuating air from within the sealed pack through the suction port and filling the sealed pack with gas from the pressurised gas source through the filling port.

The apparatus may include a control valve between the or at least one gas port and the source of vacuum and/or pressurised gas source, and the method may comprise controlling operation of the at least one control valve to control communication of the source of vacuum and/or pressurised gas source with the or at least one gas port.

The method may comprise controlling operation of the or at least one control valve by means of a controller connected to the or at least one control valve.

The or one of the support plate(s) may include a sensor element, and the method may comprise the sensor element detecting when a pack is supported in abutment with the support plate(s) and actuating the or at least one control valve to communicate the source of vacuum and/or pressurised gas source with the or at least one gas port when it is detected that a pack is in abutment with the support plate.

The method may further comprise forming an outer box around the sealed package at a packing station and the handling mechanism conveying the sealed package to the packing station.

The method may further comprise applying an adhesive to the sealed package or to an interior surface of the outer box using an adhesive applicator to bond the sealed package to the outer box with the adhesive applied over the or at least one valve of the sealed package.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a front perspective view of a smoking article pack manufactured using an apparatus and method of a first embodiment of the present invention;

FIG. 2 shows a schematic view of a pack manufacturing apparatus of a first embodiment of the present invention;

FIG. 3 shows an enlarged view of a portion of the schematic apparatus of FIG. 2;

FIG. 4 shows a cross-sectional view of the portion of the apparatus along the line X-X shown in FIG. 3 in contact with a smoking article pack being produced;

FIG. 5 shows a front perspective view of a smoking article pack manufactured using an apparatus and method of a second embodiment of the present invention;

FIG. 6 shows a schematic view of a pack manufacturing apparatus of a second embodiment of the present invention; and

FIG. 7 shows a cross-sectional view similar to that of FIG. 4, but of a portion of the apparatus shown in FIG. 6 in contact with a smoking article pack as shown in FIG. 5 being produced.

DETAILED DESCRIPTION

FIG. 1 shows a pack of smoking articles 1 manufactured using an apparatus and method of the present invention. (For the purposes of brevity of the description, smoking articles 2 will hereafter be referred to as “cigarettes 2”). The pack 1 comprises a bundle of cigarettes 2 wrapped in an outer barrier layer 3. The outer barrier layer 3 is sealed around the bundle of cigarettes 2 to provide an air-tight package enclosing the cigarettes 2. The elongate side edges of the pack 1 are formed as fin seals as part of the air-tight sealing configuration of the barrier layer 3. The outer barrier layer 3 also includes a one-way valve 4 on the outer surface of the pack 1 configured to allow air to be drawn out of the pack 1 to establish a negative pressure within the pack 1, but to prevent air returning back into the pack 1. The pack 1 includes a cigarette access aperture (not shown) which is formed by a flap cut from the barrier layer 3 and which is covered by a re-sealable label 5. The re-sealable label 5 makes a substantially air-tight seal with the barrier layer 3.

In the exemplary embodiment shown, the one-way valve 4 comprises a pad 6 bonded around its perimeter over a small aperture 7 in the barrier layer 3, and including moveable flaps 8 that rest against the surface of the barrier layer 3 beneath the pad 6. When a vacuum source is applied to the valve 4, air is drawn from within the pack 1 through the small aperture 7 in the barrier layer 3, and the flaps 8 lift away from the barrier layer 3 slightly to allow the air to exit the pack 1. However, once the vacuum source is removed, the negative pressure within the pack 1 pulls the flaps 8 tight against the underlying barrier layer 3 to make a seal therewith which prevents any ambient atmosphere from being able to pass back into the pack 1. The pack 1 is sufficiently sealed to allow the reduced pressure to be maintained within the pack 1 until the pack 1 is opened for the first time by lifting the re-sealable label 5 to open the access aperture.

The partial vacuum provided within the pack 1 helps preserve the flavour and freshness of the cigarettes during transport, storage and retail display until purchased by a consumer for use. When the pack 1 is opened, ambient air rushes into the pack to equalise the negative pressure, which gives an audible indicator to the consumer of the first opening of the pack 1.

The material of the barrier layer 3 is substantially gas-impermeable and may, in particular, be impermeable to oxygen to prevent ingress of oxygen into the pack 1. Also, the gas-impermeable material of the barrier layer 3 prevents movement of moisture through the barrier material, so the moisture content within the pack 1 remains constant and is not affected by external conditions.

FIG. 2 shows a schematic view of a pack manufacturing apparatus 10 of the present invention, and shows the production process steps. The apparatus 10 comprises an inner frame station 11, a barrier wrap station 12, a lifting station 13, a transfer wheel 14, a packing station 15 and an outer wrap station 16.

The inner frame station 11 receives generally cuboidal bundles of cigarettes 2 and flat card inner frame blanks 17. At the inner frame station 11, the inner frame blank 17 is folded around the bundle of cigarettes 2, to form a combined inner frame and cigarette bundle 18. The inner frame blank 17 is folded around the cuboidal bundle of cigarettes so as to extends at least partially extend over both the front and rear faces of the bundle, that is the largest faces of the cuboidal bundle. The inner frame blank 17 is also folded to at least partially extend over the long side faces of the bundle between the front and rear faces. The combined inner frame and cigarette bundle 18 is then transferred to the barrier wrap station 12.

The barrier wrap station 12 receives the combined inner frame and cigarette bundle 18. The barrier wrap station 12 also receives a continuous web 19 of barrier layer 3 material which has been pre-formed, at regularly spaced intervals, with cuts defining the cigarette access apertures (not shown) covered with re-sealable labels 5, and small apertures 7 over which the valves 4 are bonded. The barrier wrap station 12 cuts a section of the continuous web 19 of barrier layer material and wraps the cut web section around the combined inner frame and cigarette bundle 18, sealing the edge flaps to form an sealed wrapped cigarette package 20. The wrapped package 20 includes a valve 4 on a lower portion of the front face—namely on the larger rectangular face over which the majority of the re-sealable label 5 is adhered, and proximate an opposite end of the face to the re-sealable label 5.

The wrapped package 20 is subsequently to be conveyed to the packing station 15 and the apparatus 10 includes a lifting station 13 and a transfer wheel 14 to convey the wrapped package 20 from the barrier wrap station 12 to the packing station 15. The transfer wheel 14 comprises a hub 21 and a plurality of pockets 22 disposed around the perimeter of the hub 21. The lifting station 13 comprises a handling mechanism which is configured to transfer the wrapped packages 20 from the barrier wrap station 12 to a pocket 22 of the transfer wheel 14. As the transfer wheel 14 rotates it conveys the wrapped packages 20 to the packing station 15. The handling mechanism is shown in more detail in FIG. 3 and comprises a pair of support plates, a lifting plate 23 and a follower plate 24. Each plate 23, 24 is mounted to a respective rotatable support arm 25, 26 which are moveable to raise and lower the lifting and follower plates 23, 24. In use, a wrapped package 20 is held between contact faces 27, 28 of the lifting and follower plates 23, 24 as the support arms 25, 26 rotate to lift the wrapped package 20 into position into a pocket 22 of the transfer wheel 14.

A gas port in the form of a suction port is associated with the follower plate 24. The suction port comprises a gas hole to act as a suction hole 29 formed in the follower plate 24 which is open at the contact face 28, extends through the follower plate 24 and is connected to a gas hose to act as a vacuum hose 30 on the opposite side of the follower plate 24 to the contact face 28. The vacuum hose 30 is fluidly connected to a vacuum tank 31 via a control valve 32, and the vacuum tank 31 is connected to a vacuum pump 33. The control valve 32 may be a solenoid valve or may be actuated by a solenoid. When the control valve 32 is actuated into an open position, the vacuum causes air to be sucked through the suction hole 29 into the vacuum tank 31. The control valve 32 may be connected to a controller (not shown) of the apparatus 10 to control operation of the control valve.

The apparatus 10 is configured such that when the wrapped package 20 is held between the lifting and follower plates 23, 24, the suction hole 29 is aligned with the valve 4. During the lifting step of the wrapped package 20 from the barrier wrap station 12 to the transfer wheel 14, the control valve 32 is actuated to open and thereby evacuate air from within the wrapped package 20 to form an evacuated wrapped package 34. As the evacuated wrapped package 34 reaches the transfer wheel 14, the control valve 32 is closed and the valve 4 prevents ambient air from re-entering the evacuated wrapped package 34, thereby leaving the interior of the evacuated sealed wrapped package 34 as a partial vacuum. The inner frame 17 extending over both front and rear faces of the cigarette bundle, as well as the side faces, supports the barrier material 3 and provides protection to the cigarettes to prevent them being crushed under the force of the vacuum within the evacuated wrapped package 34.

The packing station 15 receives evacuated wrapped packages 34 from the transfer wheel 14, and also receives card outer box blanks 35, and folds and glues the box blanks 35 around the evacuated wrapped packages 34 to form hinged lid packs 36 containing the evacuated wrapped packages 34.

The hinged lid packs 36 proceed to the outer wrap station 16 where they are enveloped in an outer film wrap in a conventional manner to produce a wrapped hinged lid pack 37.

It can be seen from FIG. 4 that the contact face 28 of the follower plate 24 includes a circular seal 38 around the suction hole 29. This is to facilitate an airtight seal between the wrapped package 20 and the follower plate 23 so that only air from within the wrapped package 20 is evacuated by the applied vacuum and ambient air is not drawn into the vacuum hose 30 which could affect the effectiveness of the evacuation process. However, the circular seal is not an essential aspect of the invention and may alternatively be omitted, with the applied vacuum sufficient to suck the wrapped package 20 against the follower plate 23 during the evacuation process. It should also be appreciated that the seal 38 and valve 4 are shown in FIG. 4 with exaggerated dimensions for clarity of illustration. In practice, the height of the seal 38 and the valve 4 would be less than shown and the wrapped package 20 would not be spaced from the follower plate 24 but instead, would abut the follower plate 24.

In the above-described apparatus and method, air is evacuated from the pack 1 to provide a negative pressure within the pack 1, namely a pressure below atmospheric pressure such as an at least partial vacuum. However, the apparatus and method of pack manufacture of the invention is not intended to be limited to such embodiments. In an alternative embodiment of the invention, packs may be produced with a gas other than air within the sealed pack. For example, the air within the pack during manufacture may be evacuated and replaced by a less reactive or inert gas, or may be displaced by introduction of a less reactive or inert gas. For the purposes of the description hereafter, any such gas will be referred to as “inert gas”. The inert gas may be provided at a positive pressure, that is, a pressure elevated above atmospheric pressure.

FIG. 5 shows a pack of smoking articles 101 manufactured using an apparatus and method of a second embodiment of the present invention. The pack 101 is similar to the pack 1 shown in FIG. 1, and like features retain the same reference numerals. However, a difference with the pack of FIG. 5 is that a one-way valve 104 is provided on the inner surface of the barrier layer 3. The valve 104 is configured to allow gas to be introduced into the pack 101 but to prevent gas from escaping from the pack 101.

The one-way valve 104 comprises a pad bonded around its perimeter over a small aperture 7 in the barrier layer 3, and includes moveable flaps that rest against the inner surface of the barrier layer 3 beneath the pad. When a source of pressurised gas is applied to the valve 104, the gas flows into the pack 101 through the small aperture 7 in the barrier layer 3, and the flaps of the valve 104 lift away from the barrier layer 3 slightly to allow the gas to enter the pack 101. However, once the gas source is removed, the pack 101 is provided with an elevated internal gas pressure relative to atmospheric pressure. This elevated pressure pushes the flaps against the underlying barrier layer 3 to make a seal therewith which prevents the inert gas within the pack 101 from being able to escape from the pack 101. The pack 101 is sufficiently sealed to allow the elevated pressure to be maintained within the pack 101 until the pack 1 is opened for the first time by lifting the re-sealable label 5 to open the access aperture.

The atmosphere of inert gas provided within the pack 101 helps preserve the flavour and freshness of the cigarettes during transport, storage and retail display until purchased by a consumer for use. When the pack 101 is opened, the inert gas rushes out of the pack 101 to equalise the elevated pressure, which gives an audible indicator to the consumer of the first opening of the pack 101.

The material of the barrier layer 3 is substantially gas-impermeable and may, in particular, be impermeable to oxygen to prevent ingress of oxygen into the pack 1. Also, the gas-impermeable material of the barrier layer 3 prevents movement of moisture through the barrier material, so the moisture content within the pack 1 remains constant and is not affected by external conditions.

FIG. 6 shows a schematic view of a pack manufacturing apparatus 110 of a second embodiment of the present invention. The apparatus is similar to that of the first embodiment shown in FIG. 2. Like features retain the same reference numerals and description thereof will not be repeated. A difference in the apparatus 110 of the second embodiment is that the barrier wrap station 12 wraps the cut web section from the continuous web 19 of barrier material around the combined inner frame and cigarette bundle 18 such that the resulting wrapped package 20 includes a valve 104 on an inside of a lower portion of the front face. It will be appreciated therefore that the web 19 is provided with the valves 104 on the opposite side of the web 19 to the re-sealable labels 5 (as represented by the valves 104 being shown in dashed lines in FIG. 6).

In addition to the above, the apparatus no include the gas port in the form of a filling port associated with the follower plate 24. The filling port is similar to the suction port of the apparatus 10 of the first embodiment, and comprises a gas hole to act as a filling hole 29 (see FIG. 7) formed in the follower plate 24 which is open at the contact face 28, extends through the follower plate 24 and is connected to a gas hose to act as a filling hose 30 on the opposite side of the follower plate 24 to the contact face 28. The filling hose 30 is fluidly connected to a pressurised gas supply 131 via a control valve 32. The pressurised gas supply may comprise an inert gas or less reactive gas than air. For example, the gas may comprise nitrogen or may comprise SF₆—sulphur hexafluoride. The control valve 32 may be a solenoid valve or may be actuated by a solenoid. When the control valve 32 is actuated into an open position, the gas from the pressurised gas supply 131 flows through the filling hole 29 into the pack 101. The control valve 32 may be connected to a controller (not shown) of the apparatus no to control operation of the control valve.

The apparatus no is configured such that when the wrapped package 20 is held between the lifting and follower plates 23, 24, the filling hole 29 is aligned with the valve 104 and small aperture 7 in the barrier layer 3. During the lifting step of the wrapped package 20 from the barrier wrap station 12 to the transfer wheel 14, the control valve 32 is actuated to open and thereby fill the wrapped package 20 with inert gas to form a filled package 134. As the filled package 134 reaches the transfer wheel 14, the control valve 32 is closed and the valve 104 prevents gas within the filled package 134 from escaping.

The packing station 15 receives filled wrapped packages 134 from the transfer wheel 14, and also receives card outer box blanks 35, and folds and glues the box blanks 35 around the filled wrapped packages 134 to form hinged lid packs 36 containing the filled wrapped packages 134. The hinged lid packs 36 then proceed to the outer wrap station 16 to be enveloped in an outer film wrap as described previously.

It can be seen from FIG. 7 that the contact face 28 of the follower plate 24 includes a circular seal 38 around the filling hole 29. This is to facilitate an airtight seal between the wrapped package 20 and the follower plate 28 to prevent leakage of gas from the pressurised gas supply 131 during a filling process. However, the circular seal is not an essential aspect of the invention and may alternatively be omitted.

In use of the apparatus no of the second embodiment, the wrapped package may comprise a further valve (not shown) to allow air initially within the wrapped package 20 to exit the wrapped package by being displaced as the inert gas is introduced. The further valve may be configured to be permanently sealed closed during the process of filling the wrapped package 20 with inert gas. For example, a pressure or heat activated adhesive may be provided on the further valve which is activate by application of heat or pressure to the further valve once pressurised inert gas has been introduced into the wrapped package to displace the air initially therein. A support plate 23, 24 may include a heating element to activate the adhesive. Once the further valve is sealed closed, further escape of the inert gas is prevented and the one-way valve 104 acts as described above to retained the elevated pressure within the filled wrapped package 134. Alternatively, the handling mechanism may include a sealing means to seal closed the further valve once the air has been displaced from the wrapped package 20. The further valve may be omitted and the wrapped package may comprise a second aperture in the barrier material 3 which is sealed closed by the sealing means once the air has been displaced from the wrapped package 20. The sealing means may apply an adhesive pad over the further valve or second aperture.

An apparatus 210 of a third embodiment of the invention may be configured to both evacuate air from the wrapped package 20 and then fill the evacuated package with an inert gas. Such an apparatus is also shown in FIG. 6, and additionally includes the features shown in dashed lines. The apparatus includes all features of the apparatus 10 of the first embodiment shown in FIG. 2, in addition to the pressurised gas supply 131 of the apparatus 110 of the second embodiment. In the third embodiment, the apparatus 210 include a gas port associated with the follower plate 24 which serves as both a suction port and a filling port. In the present disclosure, the term “gas port” may therefore be taken to encompass both a suction port or a filling port as described above, and also to encompass a port which serves as both a filling and suction port.

The gas port comprises a gas hole 29 as in the apparatuses 10, 110 of the previous embodiments. The gas port is connected to a gas hose 30 on the opposite side of the follower plate 24 to the contact face 28. The gas hose 30 is fluidly connected to both a vacuum tank 31 and a pressurised gas supply 131 via a control valve 32. The vacuum tank 31 and pressurised gas supply 131 are as described previously. The control valve 32 may be a solenoid valve or may be actuated by a solenoid. The control valve 32 is operable to selectively connect the vacuum tank 31 or the pressurised gas supply 131 to the gas hole 29. The control valve 32 may also close off both the vacuum tank 31 and pressurised gas supply 131 from the gas hole 29. The control valve 32 may be connected to a controller (not shown) of the apparatus 210 to control operation of the control valve.

In operation of the apparatus 210 of the third embodiment of the invention, the wrapped package 20 is held between the lifting and follower plates 23, 24 with the gas hole 29 aligned with the valve 104 and small aperture 7 in the barrier layer 3. During the lifting step of the wrapped package 20 from the barrier wrap station 12 to the transfer wheel 14, the control valve 32 is actuated to first connect the vacuum tank 31 with the gas hole 29 to evacuate air from within the wrapped package 20. Then the control valve 32 would close the connection with the vacuum tank 31 and connect the pressurised gas supply 131 with the gas hole 29 to fill the wrapped package 20 with inert gas to form a filled wrapped package 134. As the filled package 134 reaches the 3 o transfer wheel 14, the control valve 32 is closed and the valve 104 prevents gas within the filled package 134 from escaping. In order to allow the valve 104 to permit air to be evacuated from the pack, the gas port may comprise a projection or other feature (not shown) to extend through the small aperture 7 to hold the valve 104 open.

In the exemplary embodiments of the apparatus 10, 110, 210 of the invention, the gas hole 29 and gas hose 30 are provided on the follower plate 24, although the invention is not intended to be limited to this configuration and the gas hole 29 and gas hose 30 may alternatively be provided on the lifting plate 23. In such an alternative configuration, the wrapped package 20 may be provided to the lifting station 13 with the front face facing downwards, namely so that the valve 4, 104 faces the lifting plate 23. The gas hole 29 would be provided in the lifting plate 23 and positioned so that it is disposed over the valve 4, 104 when the wrapped package 20 is held between the lifting and follower plates 23, 24. Alternatively, the wrapped package 20 could be configured with the valve 4, 104 disposed on an opposite, rear face of the package to face downwards, namely to face and be aligned with the gas hole 29 on the lifting plate 23.

In addition to the above, in an alternative embodiment, a gas port may be provided on both the follower and lifting support plates 23, 24 within the scope of the invention. This may enable a wrapped package 20 to be conveyed between the support plates either facing upwards or downwards, and one of the two gas ports may still be operable in alignment with the valve 4, 104 in the wrapped package 20 to evacuate air from within the package 20 or to fill the wrapped package 20 with inert gas. Also, the wrapped packages 20 supplied to the handling mechanism may comprise two valves 4, 104, one on each opposite face of the wrapped package 20. The valves 4, 104 may be positioned on the packages to correspond to the positions of the gas ports on the support plates 23, 24. Air may be evacuated from within, or inert gas may be introduced into, the wrapped packages 20 through both valves 4, 104 as the wrapped packages 20 are conveyed by between the support plates 23, 24 by the handling mechanism.

In a further variant of the above alternative embodiment having two gas ports, one on each support plate 23, 24, one gas port may comprise a suction port and one gas port may comprise a filling port. In operation, inert gas may be introduced into the wrapped package 20 through one gas port while the air initially within the wrapped package 20 may be evacuated though the other gas port. The wrapped package 20 may include two valves 4, 104. Inert gas may be introduced through a first valve 104 and air may be evacuated through a second valve 4. The second valve 4 may be sealed closed by a sealing means as described above during the evacuation/filling process to enable the wrapped package to be filled with the inert gas to an elevated pressure above atmospheric pressure. The sealing means would seal the second valve closed so that the inert gas is no longer able to escape therethrough.

The apparatuses 10, 110, 210 of the invention described above comprise a packing station 15 which receives evacuated/filled wrapped packages 34, 134 from the transfer wheel 14 and folds and glues the box blanks 35 around the evacuated/filled wrapped packages 34, 134. The evacuated/filled wrapped packages 34, 134 may be bonded to the inside of the hinged lid packs 36 by adhesive to retain them in place. The apparatuses 10, 110, 210 may include an adhesive applicator to apply adhesive to the evacuated/filled wrapped packages 34, 134. The adhesive applicator may apply the adhesive over the valve 4, 104, further valve, second valve 4, or second aperture in the barrier material 3 in the evacuated/filled wrapped packages 34, 134 in the above-described embodiments. The adhesive may thereby seal the respective valve/aperture closed once the evacuated/filled wrapped package 34, 134 is bonded within the hinged lid pack 36. This adhesive may thereby serve as the above-described sealing means. The adhesive may also further reinforce and ensure the integrity of the airtight seal of the valve 4, 104.

In the above-described first embodiment of the invention, air is evacuated from the wrapped package 20 to form a partial vacuum therein. It will be appreciated that varying degrees of air may be evacuated from the wrapped package 20, but that the pressure within the wrapped package 20 will be reduced to a negative pressure, that is, a pressure lower than ambient atmospheric pressure. It will also be appreciated that not only air may be evacuated from the wrapped package 20, and any gas that is present at that time can be evacuated.

The partial vacuum within the evacuated wrapped package 34 may have a pressure of less than 1 bar. In some examples, the partial vacuum is less than 500 millibar, for example between 40 and 300 millibar. In other embodiments, the partial vacuum is less than 150 millibar, preferably about 80 millibar. However, it will be appreciated that the partial vacuum within the wrapped package 20 may be any value less than 1 bar.

The apparatuses 110, 210 and methods of the second and third embodiments of the invention are described above as producing the filled package 134 with the inert gas at an elevated pressure. However, the invention is not intended to be limited to such an embodiment and the apparatus and method may fill the wrapped packages 20 with inert gas to at or around atmospheric pressure. The valve in the pack may enable filling and optionally also evacuation of air within the pack before filling, and the valve sealed by a sealing means as described above after filling the wrapped package 20 with inert gas to at or around atmospheric pressure.

The invention is not intended to be limited to any particular location of gas port(s) on the support plate(s), and either may be located at any position within the scope of the invention, such that a valve(s) of the wrapped packages aligns with the gas port(s) of the support plates.

The invention is not intended to be limited to any particular location of control valve 32. The or a control valve 32 may be located on the support plate(s), and may be provided within or proximate the or each gas hole 29.

Although the apparatuses 10, 110, 210 of the invention are shown and described as comprising the gas port extending through one of the support plates, such as the is follower plate 24, the invention is not intended to be limited to this particular configuration. In an alternative embodiment, a gas port may be provided adjacent one of the support plates such that a gas hole does not extend through one of the support plates. For example, the gas port may be fixedly connected to a support plate and the support plate configured such that the support plate abuts part of a face of a wrapped package and the adjacent gas port engages another part of the face of the wrapped package adjacent the support plate, to evacuate air from within the wrapped package. In such an embodiment, the support plate may be reduced in size so that it does not cover the entire surface area of the face of the wrapped package with which it abuts.

In an optional embodiment of the apparatus of the invention, at least one of the support plates 23, 24 may include a sensor element to detect when a wrapped package 20 is being held by, or is in contact with the support plates 23, 24. This may comprise, for example, an electrical sensor or, a mechanical button that is depressed by a wrapped package 20 when in contact with the respective support plate 23, 24. The sensor element may be connected to the control valve 32 to operate the control valve 32 when it is detected that a wrapped package 20 is held between the lifting and follower plates 23, 24. For example, if the control valve 32 is connected to a solenoid, the solenoid may be actuated to open the control valve 32 in response to detection of a wrapped package 20 by the sensor element. The connection may be by means of an electrical contact actuated by the sensor element. Alternatively, the sensor element may be connected to the controller to provide a signal to the controller when a wrapped package is in abutment with the lifting or follower plate 23, 24 to allow the controller to actuate the control valve 32. With such a sensor element, the application of the vacuum to evacuate the wrapped package 20, and/or the supply of inert gas to fill the wrapped package 20, can be controlled only to operate in coordination with when a wrapped package is held in the handling mechanism.

In an advantageous embodiment of the apparatuses 10, 110, 210 of the invention, the gas port may be wider than the valve 4, 104. For example, in embodiments in which the valve 4, 104 and gas port are circular, the gas port may be of a larger diameter than the valve 4, 104. For example, the seal 38 and/or the gas hole 29 may be of a larger diameter than the diameter of the valve 4, 104. In other configurations of valve 4, 104 and gas port, such as square or rectangular, the outer dimensions of the gas port may be greater than the outer dimensions of the valve 4, 104. Such an arrangement may advantageously help ensure the gas port always locates over the valve 4, 104, and may allow a degree of tolerance in the positioning of the wrapped package 20 between the support plates 23, 24. Such a degree of tolerance means that the wrapped package 20 does not need to be in exact registration with the support plates 23, 24 in each operation of the handling mechanism, and may allow for faster apparatus processing speeds and reduced cost of machinery control systems.

As used herein, the term “smoking article” includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products and other nicotine delivery product such as aerosol generation devices including e-cigarettes. The smoking article may be provided with a filter for the gaseous flow drawn by the smoker.

As used herein, the term “partial vacuum” means that pressure has been reduced by removing at least a part of the gas from within a space, for example the enclosure within the barrier material 3 of the wrapped package 20.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior apparatus and method for manufacturing a smoking article pack. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive.

They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future. 

1. An apparatus for manufacturing a sealed pack of smoking articles and modifying an internal atmosphere thereof, the apparatus comprising a handling mechanism for conveying a sealed pack of smoking articles within the apparatus, the handling mechanism including a support plate against which a pack abuts during conveyance by the handling mechanism, the support plate including a gas port, the apparatus configured such that, as a pack is conveyed by the handling mechanism in abutment with the support plate, the gas port may engage a valve formed in the pack to enable a gaseous atmosphere within the sealed pack to be modified.
 2. An apparatus according to claim 1 wherein the support plate comprises one of a pair of spaced support plates configured to retain a pack between the support plates, wherein at least one of the support plates includes the gas port.
 3. An apparatus according to claim 2 comprising a plurality of gas ports.
 4. An apparatus according to claim 3 wherein at least two gas ports are provided on the same support plate.
 5. An apparatus according to claim 3 wherein each support plate comprises a gas port.
 6. An apparatus according to claim 1 wherein the or at least one gas port includes a sealing element to facilitate formation of an airtight seal between the gas port(s) and the pack.
 7. An apparatus according to claim 1 wherein the or at least one gas port comprises an aperture extending through the support plate.
 8. An apparatus according to claim 1 wherein the or each gas port comprises a suction port connected to a vacuum source to enable air to be evacuated from a pack through the suction port.
 9. An apparatus according to claim 1 wherein the or each gas port comprises a filling port connected to a pressurised gas source to enable a pack to be filled with gas from the pressurised gas source through the filling port.
 10. An apparatus according to claim 1 wherein the or each gas port comprises a suction and filling port selectively connected to a vacuum source and a pressurised gas source to enable air to be evacuated from a pack through the gas port and for a pack to be filled with gas from the pressurised gas source through the gas port.
 11. An apparatus according to claim 3, wherein a first gas port comprises a suction port connected to a vacuum source to enable air to be evacuated from a pack through the suction port, and a second gas port comprises a filling port connected to a pressurised gas source to enable a pack to be filled with gas from the pressurised gas source through the filling port.
 12. An apparatus according to claim 8 wherein a control valve is provided between the or each gas port and the source of vacuum and/or pressurised gas supply, and the or each control valve is operable to control communication of the source of vacuum and/or pressurised gas supply with the or each gas port.
 13. An apparatus according to claim 12 wherein the or one of the support plate(s) includes a sensor element configured to detect when a pack is supported in abutment with the support plate, wherein the or each control valve is configured to be actuated when it is detected that a pack is in abutment with the support plate.
 14. (canceled)
 15. (canceled)
 16. An apparatus according to claim 1 comprising a wrapping station configured to wrap and seal a bundle of smoking articles with a barrier material to form a sealed package and to provide a valve on at least one face of the package, and to provide the sealed package to the handling mechanism.
 17. An apparatus according to claim 16 wherein the wrapping station includes a continuous web of barrier material having valves at regularly spaced intervals along the web, each valve disposed over an aperture through the barrier material, and wherein the wrapping station is configured to cut sections of barrier material from the web and to wrap and seal bundles of smoking articles such that the or each valve is consistently positioned on each sealed package.
 18. An apparatus according to claim 17 further comprising a packing station configured to form an outer box around the sealed package, wherein the handling mechanism is disposed between the wrapping station and the packing station to convey the sealed package between the wrapping station and the packing station.
 19. An apparatus according to claim 18 further comprising an adhesive applicator configured to apply an adhesive to the sealed package or an interior surface of the outer box, to bond the sealed package to the outer box with the adhesive applied over the or at least one valve of the sealed package.
 20. An apparatus according to claim 17 wherein the or at least one gas port is configured to sit over the or at least one valve on the wrapped package when engaged therewith, and the or at least one gas port is of a larger dimension than the or at least one valve.
 21. (canceled)
 22. A method of manufacturing a sealed pack of smoking articles having a modified internal atmosphere using an apparatus comprising a handling mechanism which includes a support plate having a gas port, the method comprising conveying a sealed pack of smoking articles within the apparatus using the handling mechanism with the pack abutting the support plate, engaging the gas port with a valve formed in the pack and modifying the gaseous atmosphere within the sealed pack via the valve through the gas port.
 23. A method according to claim 22 comprising conveying the pack held between the support plate and a second support plate whilst modifying the internal atmosphere within the pack.
 24. A method according to claim 22 wherein the gas port comprises a suction port connected to a vacuum source and the step of modifying the gaseous atmosphere within the sealed pack comprises evacuating air from within the sealed pack through the suction port.
 25. A method according to claim 22 wherein the gas port comprises a filling port connected to a source of pressurised gas and the step of modifying the gaseous atmosphere within the sealed pack comprises filling the sealed pack with gas from the pressurised gas source through the filling port.
 26. A method according to claim 22 wherein the gas port comprises a suction and filling port selectively connected to a vacuum source and a pressurised gas source, and the step of modifying the gaseous atmosphere within the sealed pack comprises evacuating air from within the sealed pack through the gas port and filling the sealed pack with gas from the pressurised gas source through the gas port.
 27. A method according to claim 22 wherein the apparatus comprises a first gas port comprising a suction port connected to a vacuum source and a second gas port comprising a filling port connected to a pressurised gas source, and wherein the step of modifying the gaseous atmosphere within the pack comprises evacuating air from within the sealed pack through the suction port and filling the sealed pack with gas from the pressurised gas source through the filling port.
 28. A method according to claim 22 wherein the apparatus includes a control valve between the or at least one gas port and the source of vacuum and/or pressurised gas source, the method comprising controlling operation of the at least one control valve to control communication of the source of vacuum and/or pressurised gas source with the or at least one gas port.
 29. (canceled)
 30. A method according to claim 28 wherein the or one of the support plate(s) includes a sensor element, the method comprising the sensor element detecting when a pack is supported in abutment with the support plate(s) and actuating the or at least one control valve to communicate the source of vacuum and/or pressurised gas source with the or at least one gas port when it is detected that a pack is in abutment with the support plate.
 31. A method according to claim 30 further comprising forming an outer box around the sealed package at a packing station and the handling mechanism conveying the sealed package to the packing station.
 32. A method according to claim 31 further comprising applying an adhesive to the sealed package or to an interior surface of the outer box using an adhesive applicator to bond the sealed package to the outer box with the adhesive applied over the or at least one valve of the sealed package. 